Hi Bud,
Dave's advice sits well with me, however, I'd add several things.
The penetrant should be something like WD-40 or Liquid Wrench rather than a
penetrating oil. The soaking and whacking should be done some time in
advance of actually trying to move the stud, preferably overnight.
When first attempting to move the stud, try rocking it (rotationally
speaking) so that the stud turns back and forth, loosening and tightening
back a little. The movement may be almost imperceptible at first, but be
patient. This way you don't try to force the stud through loosened corrosion
and have it gall the threads or break again. Use more penetrant. For tools,
a large vice grip would be my choice if there is clearance enough.
A totally different approach for certain circumstances is to weld a hex
head onto the top of the broken stud. Let it cool completely before rocking
it back and forth as before.
Patience!
Good luck!
Pete Thiel
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